PDF Shop Manual KOMATSU PC228US-3E0 PC228USLC-3E0 Hydraulic Excavator - 4 MB
This comprehensive shop manual is for the Komatsu PC228US-3E0 and PC228USLC-3E0 hydraulic excavators.
It contains detailed service and repair information used by professional technicians.
The manual covers everything from the engine and hydraulics to the electrical system, with step-by-step instructions and specifications.
This is the ultimate resource for keeping your Komatsu excavator in top working order.
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--- Page 1 ---
SEN01418-10
HYDRAULIC PC228US -3E0
EXCAVATOR
PC228USLC -3E0
PC228US- 40001
SERIAL NUMBERS and up
PC228USLC- 40001
--- Page 3 ---
SEN01420-10 00 Index and foreword
Disassembly and assembly of final drive assembly................................................................. 3
Removal and installation of swing machinery assembly.......................................................... 11
Disassembly and assembly of swing machinery assembly ..................................................... 13
Removal and installation of swing circle assembly .................................................................. 21
Undercarriage and frame SEN01926-02
Disassembly and assembly of track roller assembly ............................................................... 2
Disassembly and assembly of idler assembly ......................................................................... 3
Disassembly and assembly of recoil spring............................................................................. 6
Expansion and installation of track shoe assembly ................................................................. 8
Removal and installation of revolving frame ............................................................................ 10
Removal and installation of counterweight assembly .............................................................. 12
Removal and installation of maintenance counterweight (at rear of engine) ........................... 13
Removal and installation of maintenance counterweight assembly (above pump) ................. 14
Hydraulic system SEN01927-02
Removal and installation of center swivel joint assembly ........................................................ 2
Disassembly and assembly of center swivel joint.................................................................... 4
Removal and installation of hydraulic tank assembly .............................................................. 5
Removal and installation of work equipment pump ................................................................. 7
Removal and installation of control valve assembly ................................................................ 11
Disassembly and assembly of control valve assembly............................................................ 13
Disassembly and assembly of work equipment PPC valve assembly..................................... 15
Disassembly and assembly of travel PPC valve assembly ..................................................... 17
Disassembly and assembly of hydraulic cylinder assembly .................................................... 20
Work equipment SEN01928-01
Removal and installation of work equipment assembly ........................................................... 2
Cab and its attachments SEN01929-01
Removal and installation of operator’s cab assembly.............................................................. 2
Removal and installation of operator’s cab glass (Stuck glass)............................................... 4
Removal and installation of front window assembly ................................................................ 13
Removal and installation of floor frame assembly ................................................................... 14
Electrical system SEN01930-01
Removal and installation of air conditioner compressor assembly .......................................... 2
Removal and installation of air conditioner condenser assembly ............................................ 4
Removal and installation of air conditioner unit assembly ....................................................... 5
Removal and installation of machine monitor assembly .......................................................... 7
Removal and installation of pump controller assembly............................................................ 8
Removal and installation of engine controller assembly .......................................................... 9
Removal and installation of KOMTRAX communication modem assembly ............................ 11
90 Diagrams and drawings
Hydraulic diagrams and drawings SEN01439-01
Hydraulic circuit diagram ......................................................................................................... 3
Electrical diagrams and drawings SEN01440-02
Electrical circuit diagram.......................................................................................................... 3
Connector list and stereogram................................................................................................. 17
10 PC228US, USLC-3E0
--- Page 4 ---
SEN01421-02 00 Index and foreword
3. Filing method
File by the brochures in the correct order of the form number printed in the shop manual composition
table.
q Revised edition mark
When a manual is revised, the ones and tens digits of the form number of each brochure is
increased by 1. (Example: 00, 01, 02 …)
q Revisions
Revised brochures are shown in the shop manual composition table.
4. Symbols
Important safety and quality portions are marked with the following symbols so that the shop manual will
be used practically.
Symbol Item Remarks
k Safety Special safety precautions are necessary when performing work.
Special technical precautions or other precautions for preserving stan-
a Caution
dards are necessary when performing work.
4
Weight of parts of component or parts. Caution necessary when
Weight
selecting hoisting wire, or when working posture is important, etc.
3
Tightening Places that require special attention for tightening torque during
torque assembly.
2 Coat Places to be coated with adhesives, etc. during assembly.
5
Oil, coolant Places where oil, etc. must be added, and capacity.
6
Drain Places where oil, etc. must be drained, and quantity to be drained.
5. Units
In this shop manual, the units are indicated with International System of units (SI). For reference, con-
ventionally used Gravitational System of units is indicated in parentheses { }.
8 PC228US, USLC-3E0
--- Page 5 ---
SEN01421-02 00 Index and foreword
Points to remember when handling hydraulic equipment
With the increase in pressure and precision of hydraulic equipment, the most common cause of failure is dirt
(foreign material) in the hydraulic circuit. When adding hydraulic oil, or when disassembling or assembling
hydraulic equipment, it is necessary to be particularly careful.
1. Be careful of the operating environment.
Avoid adding hydraulic oil, replacing filters, or
repairing the machine in rain or high winds, or
places where there is a lot of dust.
2. Disassembly and maintenance work in the
field
If disassembly or maintenance work is carried
out on hydraulic equipment in the field, there is
danger of dust entering the equipment. It is
also difficult to check the performance after
repairs, so it is desirable to use unit exchange.
Disassembly and maintenance of hydraulic
equipment should be carried out in a specially
prepared dustproof workshop, and the perfor-
mance should be checked with special test
equipment.
3. Sealing openings
After any piping or equipment is removed, the
openings should be sealed with caps, tapes, or
vinyl bags to prevent any dirt or dust from
entering. If the opening is left open or is
blocked with a rag, there is danger of dirt
entering or of the surrounding area being
made dirty by leaking oil so never do this. Do
not simply drain oil out onto the ground, but
collect it and ask the customer to dispose of it,
or take it back with you for disposal.
4. Do not let any dirt or dust get in during
refilling operations
Be careful not to let any dirt or dust get in when
refilling with hydraulic oil. Always keep the oil
filler and the area around it clean, and also use
clean pumps and oil containers. If an oil clean-
ing device is used, it is possible to filter out the
dirt that has collected during storage, so this is
an even more effective method.
18 PC228US, USLC-3E0
--- Page 6 ---
SEN01421-02 00 Index and foreword
4) Checking muffler and exhaust pipe for damage and looseness
1] Visually check the muffler, exhaust pipe and their mounting parts for a crack and damage.
If any part is damaged, replace it.
2] Check the mounting bolts and nuts of the muffler, exhaust pipe and their mounting parts for
looseness.
If any bolt or nut is loosened, retighten it.
5) Checking muffler function
Check the muffler for abnormal sound and sound different from that of a new muffler.
If any abnormal sound is heard, repair the muffler, referring to “Troubleshooting” and “Disassembly
and assembly”.
28 PC228US, USLC-3E0
--- Page 7 ---
SEN01421-02 00 Index and foreword
Liters to U.K. Gallons
1 l = 0.21997 U.K.Gal
0 1 2 3 4 5 6 7 8 9
0 0 0.220 0.440 0.660 0.880 1.100 1.320 1.540 1.760 1.980
10 2.200 2.420 2.640 2.860 3.080 3.300 3.520 3.740 3.950 4.179
20 4.399 4.619 4.839 5.059 5.279 5.499 5.719 5.939 6.159 6.379
30 6.599 6.819 7.039 7.259 7.479 7.699 7.919 8.139 8.359 8.579
40 8.799 9.019 9.239 9.459 9.679 9.899 10.119 10.339 10.559 10.778
50 10.998 11.281 11.438 11.658 11.878 12.098 12.318 12.528 12.758 12.978
60 13.198 13.418 13.638 13.858 14.078 14.298 14.518 14.738 14.958 15.178
70 15.398 15.618 15.838 16.058 16.278 16.498 16.718 16.938 17.158 17.378
80 17.598 17.818 18.037 18.257 18.477 18.697 18.917 19.137 19.357 19.577
90 19.797 20.017 20.237 20.457 20.677 20.897 21.117 21.337 21.557 21.777
kgm to ft.lb
1 kgm = 7.233 ft.lb
0 1 2 3 4 5 6 7 8 9
0 0 7.2 14.5 21.7 28.9 36.2 43.4 50.6 57.9 65.1
10 72.3 79.6 86.8 94.0 101.3 108.5 115.7 123.0 130.2 137.4
20 144.7 151.9 159.1 166.4 173.6 180.8 188.1 195.3 202.5 209.8
30 217.0 224.2 231.5 238.7 245.9 253.2 260.4 267.6 274.9 282.1
40 289.3 296.6 303.8 311.0 318.3 325.5 332.7 340.0 347.2 354.4
50 361.7 368.9 376.1 383.4 390.6 397.8 405.1 412.3 419.5 426.8
60 434.0 441.2 448.5 455.7 462.9 470.2 477.4 484.6 491.8 499.1
70 506.3 513.5 520.8 528.0 535.2 542.5 549.7 556.9 564.2 571.4
80 578.6 585.9 593.1 600.3 607.6 614.8 622.0 629.3 636.5 643.7
90 651.0 658.2 665.4 672.7 679.9 687.1 694.4 701.6 708.8 716.1
100 723.3 730.5 737.8 745.0 752.2 759.5 766.7 773.9 781.2 788.4
110 795.6 802.9 810.1 817.3 824.6 831.8 839.0 846.3 853.5 860.7
120 868.0 875.2 882.4 889.7 896.9 904.1 911.4 918.6 925.8 933.1
130 940.3 947.5 954.8 962.0 969.2 976.5 983.7 990.9 998.2 1005.4
140 1012.6 1019.9 1027.1 1034.3 1041.5 1048.8 1056.0 1063.2 1070.5 1077.7
150 1084.9 1092.2 1099.4 1106.6 1113.9 1121.1 1128.3 1135.6 1142.8 1150.0
160 1157.3 1164.5 1171.7 1179.0 1186.2 1193.4 1200.7 1207.9 1215.1 1222.4
170 1129.6 1236.8 1244.1 1251.3 1258.5 1265.8 1273.0 1280.1 1287.5 1294.7
180 1301.9 1309.2 1316.4 1323.6 1330.9 1338.1 1345.3 1352.6 1359.8 1367.0
190 1374.3 1381.5 1388.7 1396.0 1403.2 1410.4 1417.7 1424.9 1432.1 1439.4
38 PC228US, USLC-3E0
--- Page 8 ---
SEN01423-01 01 Specification
Weight table 1
k This weight table is prepared for your reference when handling or transporting the components.
Unit: kg
Machine model PC228US-3E0 PC228USLC-3E0
Serial number 40001 and up
Engine assembly 735 735
• Engine 575 575
• Damper 6 6
• Hydraulic pump 154 154
Radiator and oil cooler assembly 126 126
Hydraulic tank and filter assembly (Not including hydraulic oil) 146 146
Fuel tank assembly (Not including fuel) 131 131
Revolving frame 1,854 1,854
Cab 251 251
Operator’s seat 27 27
Counterweight 6,060 6,060
Swing machinery 224 224
Control valve 280 280
Swing motor 51.5 51.5
Travel motor 98 x 2 98 x 2
Center swivel joint 30.3 30.3
Track frame assembly (Not including piping) 4,269 4,797
• Track frame 2,260 2,644
• Swing circle 267 267
• Idler 101 x 2 101 x 2
• Idler cushion 118 x 2 118 x 2
• Carrier roller 14 x 4 14 x 4
• Track roller 36 x 14 36 x 18
• Final drive (including travel motor) 372 x 2 372 x 2
Track shoe assembly
• Standard triple shoe (600 mm) 1,215 x 2 1,395 x 2
• Standard triple shoe (700 mm) 1,405 x 2 1,530 x 2
• Standard triple shoe (800 mm) 1,530 x 2 1,670 x 2
• Flat shoe (600 mm) 1,635 x 2 1,780 x 2
• Swamp shoe (860 mm) 1,630 x 2 1,775 x 2
• Road liner (Rubber pad type) (600 mm) 1,470 x 2 1,600 x 2
6 PC228US, USLC-3E0
--- Page 9 ---
SEN01426-00 10 Structure, function and maintenance standard
Power train 1
Power train 1
1. PPC lock solenoid valve 7. Final drive
2. Travel speed switch solenoid valve 8. Travel motor (HMV110ADT-2)
3. Swing brake solenoid valve 9. Hydraulic pump (HPV95+95)
4. Idler 10. Engine (SAA6D107E-1)
5. Center swivel joint 11. Swing motor (KMF125ABE-6)
6. Control valve 12. Swing machinery
13. Swing circle
2 PC228US, USLC-3E0
--- Page 10 ---
SEN01427-00 10 Structure, function and maintenance standard
Idler 1
4 PC228US, USLC-3E0
--- Page 11 ---
SEN01428-00
HYDRAULIC EXCAVATOR 1SHOP MANUAL
PC228US-3E0
PC228USLC-3E0
Machine model Serial number
PC228US-3E0 40001 and up
PC228USLC-3E0 40001 and up
10 Structure, function and
maintenance standard 1
Hydraulic system, Part 1
Hydraulic system, Part 1 ................................................................................................................................. 2
Hydraulic equipment layout drawing .................................................................................................... 2
Hydraulic tank ...................................................................................................................................... 4
Hydraulic pump .................................................................................................................................... 6
PC228US, USLC-3E0 1
--- Page 12 ---
SEN01428-00 10 Structure, function and maintenance standard
1. LS valve
PA : Pump port 1. Sleeve
PDP : Drain port 2. Piston
PLP : LS control pressure output port 3. Spool
PLS : LS pressure input port 4. Spring
PP : Pump port 5. Sheet
PPL : Control pressure input port 6. Sleeve
PSIG : LS mode selector pilot port 7. Plug
8. Locknut
Function
q The LS (load sensing) valve detects the load
and controls the delivery.
q This valve controls main pump delivery (Q)
according to differential pressure (dPLS)[= PP
– PLS], called the LS differential pressure (the
difference between main pump pressure (PP)
and control valve outlet port pressure (PLS)).
q Main pump pressure (PP), pressure (PLS)
(called the LS pressure) coming from the con-
trol valve output, and pressure (PSIG) (called
the LS selector pressure) from the proportional
solenoid valve enter this valve.
q The relationship between the LS differential
pressure between the main pump pressure
(PP) and LS pressure (PLS) (dPLS) [= (PP) –
(PLS)] and the pump delivery (Q) changes as
shown in the diagram according to LS selector
current (ISIG) of the LS-EPC valve.
q If (ISIG) changes from 0 to 1A, setting force of
the spring changes, too. As the result, the
specified median of the pump delivery volume
switching point changes as shown in the dia-
gram. It will change in the range of 0.69 to 2.2
MPa {in the range of 7.0 to 22.0 kg/cm2}.
12 PC228US, USLC-3E0
--- Page 13 ---
SEN01428-00 10 Structure, function and maintenance standard
q The relationship between the average pump
pressure (PP1 + PP2)/2 and servo piston (9) in
terms of their positions can be represented by
the broken line in the figure springs (4) and (6)
form the double springs.
q The relationship between the average pump
pressure (PP1 + PP2)/2 and average pump
delivery (Q) becomes as shown below.
q If command voltage (X) sent to PC-EPC valve
solenoid (1) increases further, the relationship
between average pump pressure (PP1 + PP2)/
2, and pump delivery (Q) is proportional to the
force of the PC-EPC valve solenoid and moves
in parallel.
q Namely, the force of PC-EPC valve solenoid
(1) is added to the pushing force to the right
because of the pump pressure applied to the
spool (3), so the relationship between the aver-
age pump pressure (PP1 + PP2)/2 and the
pump delivery (Q) moves from (A) to (B) as the
command current (X) is increased.
22 PC228US, USLC-3E0
--- Page 14 ---
SEN01429-01 10 Structure, function and maintenance standard
Sectional view
(1/5)
4 PC228US, USLC-3E0
--- Page 15 ---
SEN01429-01 10 Structure, function and maintenance standard
CLSS 1
Outline of CLSS
Features Configuration
CLSS stands for Closed center Load Sensing Sys- q CLSS is configured with variable capacity pis-
tem, which has the following characteristics: ton pumps, control valves, and respective
actuators.
q Fine control not influenced by load q The hydraulic pump is configured with pump
q Controllability enabling digging even with fine body, PC valve and LS valve.
control
q Ease of compound operation ensured by flow
divider function using area of opening of spool
during compound operations
q Energy saving using variable pump control
14 PC228US, USLC-3E0
--- Page 16 ---
SEN01429-01 10 Structure, function and maintenance standard
Pressure compensation valve
1. During independent operation and under maximum load pressure
(If the load pressure is higher than other work equipment during a combined operation)
1. Hydraulic pump 4. Piston
2. Valve 5. Spring
3. Shuttle valve 6. LS shuttle valve
Function q As principle, port (C) and spring chamber (E)
q Pressure compensation valve works as the are not interconnected in an integrated pres-
load check valve. sure compensation valve.
q If the pump pressure (LS pressure) is lower q If high peak pressure is generated at port (C),
than the load at port (c), shuttle valve (3) in valve (7) does not collide with the valve cham-
pressure compensation valve piston (4) inter- ber.
connects spring chamber (E) and port (C). q With a bucket valve, etc., port (C) and spring
q The force of spring (5) operates piston (4) and chamber (E) are designed to interconnect
valve (2) to the closing direction. before valve (7) is seated.
Integrated pressure compensation valve
q High stress may occur when valve (2) collides
with valve chamber seat portion (C) if a high
peak pressure is generated in the actuator cir-
cuit or repetitive peak pressure occurs continu-
ously (example: when using the breaker).
q To prevent this, a pressure compensation
valve with integrated valve (2) and piston (4) is
used.
q With the present machine, this device is
adopted for the bucket valve (cylinder bottom)
and the service valve.
24 PC228US, USLC-3E0
--- Page 17 ---
SEN01429-01 10 Structure, function and maintenance standard
2. When flows from the pumps are divided [if pilot pressure (PS) is ON]
Operation
q Pilot pressure (PS) turns ON, and output pres-
sure from the PPC valve shifts main spool (1)
to the left, and ports (E) and (F) are divided.
q Pressurized oil discharged from the two pumps
are sent to respective control valves.
P1 pressure: To bucket, L.H. travel, and boom
P2 pressure: To swing, R.H. travel, and arm
q LS spool (3) too shifts to the left under the out-
put pressure from the PPC valve, intercon-
nects ports (A) and (C) and divides other ports.
q Forwards LS pressure led from each control
valve spool to LS circuits (5), (6), (7) and (8) to
respective control valves.
34 PC228US, USLC-3E0
--- Page 18 ---
SEN01429-01 10 Structure, function and maintenance standard
2. When the boom is in neutral
Operation
q Moves the lever to neutral with the boom
raised.
q Pressurized oil flown inside poppet (5) from
orifice (a) of poppet (5) is closed by pilot piston
(2).
q The holding pressure of boom cylinder bottom
works on the ring-shaped area (S) caused by
the difference between outside diameter (d1)
of poppet (5) and seat diameter (d2) to move it
to the right.
q The sum of this force and the force of spring
(4) closes poppet (5).
q Pressurized oil from the control valve and the
holding pressure of the boom cylinder bottom
are shut off.
44 PC228US, USLC-3E0
--- Page 19 ---
SEN01429-01 10 Structure, function and maintenance standard
Variable pressure compensation valve
(Installed to the service valve)
A. Pump discharge pressure (P) (From service
valve spool)
B. Cylinder port
C. Load pressure of other work equipment
1. Valve
2. Spring
3. Sleeve
4. Poppet
5. Spring
6. Screw
7. Locknut
8. Cap
Function
q Regulates flow distribution to the service valve
when the service valve (attachment) and the
work equipment valve (boom raising, etc.) are
operated together. (Equivalent surface area
ratio variable)
q Pressurized oil from the service valve spool is
applied to the left side of valve (1) and is led to
chamber (g) via orifice (a).
q LS pressure is led to chamber (e) via orifice
(d).
q Pressurized oil of cylinder port is led to cham-
ber (h) via passage (c) and orifice (f).
q The force of spring (2) acts on valve (1), and
the force of spring (5) acts on poppet (4).
q The force of spring (5) can be adjusted with
screw (6).
54 PC228US, USLC-3E0
--- Page 20 ---
SEN01429-01
PC228US, 228USLC-3E0 Hydraulic excavator
Form No. SEN01429-01
© 2010 KOMATSU
All Rights Reserved
Printed in Japan 09-10
64
--- Page 21 ---
SEN01430-01 10 Structure, function and maintenance standard
10 PC228US, USLC-3E0
--- Page 22 ---
SEN01430-01 10 Structure, function and maintenance standard
Solenoid valve
PPC lock, 2-stage relief, swing brake, travel speed, travel junction, and merge-divider solenoid valves
1. PPC lock solenoid valve 8. Moving core
2. 2-stage relief solenoid valve 9. Coil
3. Travel speed solenoid valve 10. Spool
4. Swing brake solenoid valve 11. Block
5. Travel junction solenoid valve 12. Spring
6. Merge-divider solenoid valve
7. Connector
20 PC228US, USLC-3E0
--- Page 23 ---
SEN01430-01 10 Structure, function and maintenance standard
Operation of parking brake
1) When starting travel
q As the travel lever is operated, pressurized oil
from the pump activates counterbalance valve
spool (19), opening the parking brake circuit.
q The pressurized oil is conducted to chamber
(e) of brake piston (12) and compresses spring
(11), pushing piston (12) toward left.
q Since the pushing force to plate (13) and disc
(14) disappears, plate (13) is separated from
disc (14) and the brake is released.
30 PC228US, USLC-3E0
--- Page 24 ---
SEN01430-01 10 Structure, function and maintenance standard
Reverse prevention valve
40 PC228US, USLC-3E0
--- Page 25 ---
SEN01431-00 10 Structure, function and maintenance standard
Dimensions of components 1
1. Dimension of arm
4 PC228US, USLC-3E0
--- Page 26 ---
10 Structure, function and maintenance standard SEN01433-03
Operation of system 1 Stopping engine
Starting engine q When detecting that the starting switch is set to
q When the starting switch is turned to the the “STOP” position, the engine controller cuts
START position, the starting signal flows to the the signal of the supply pump drive solenoid to
starting motor. Then, the starting motor turns to stop the engine.
start the engine.
When it happens, the engine controller checks
the signal voltage from the fuel control dial and
sets the engine speed to the speed set by the
fuel control dial.
Engine speed control
q The fuel control dial sends a signal voltage cor-
responding to the rotation angle to the engine
controller.
The engine controller sends a driving signal to
the supply pump depending on the signal volt-
age to control the fuel injection pump, and
eventually controls the engine speed.
PC228US, USLC-3E0 3
--- Page 27 ---
10 Structure, function and maintenance standard SEN01433-03
PC228US, USLC-3E0 13
--- Page 28 ---
10 Structure, function and maintenance standard SEN01433-03
5. Auto-warm-up and overheat prevention function
Function
q The engine automatic warm-up function
increases the engine speed to warm up the
engine if coolant temperature is too low after
the engine starts.
q The overheat prevention function reduces the
pump load when coolant or hydraulic oil tem-
perature is too high during operation to protect
the engine from overheating.
PC228US, USLC-3E0 23
--- Page 29 ---
10 Structure, function and maintenance standard SEN01433-03
2) Oil pressure sensor
1. Sensor
2. Connector
Function q The relationship between the pressure applied
q The pump pressure sensor is installed to the to sensors (P) and output voltage (E) is shown
input circuit of the control valve. in the figure below.